Portable Band Saw

ABSTRACT

A portable band saw includes a serviceable/replaceable bumper system for allowing the band saw to be easily repaired if damaged from being dropped. An auxiliary handle is adjustably mounted to the band saw and is releasable from its position if subjected to a large force so as to avoid damage to the handle and tool housing. An adjustable guide shoe includes a toolless adjustment. The front and rear section of the band saw are disposed on opposite sides of a polymeric field case. Compression rods are used to isolate compression forces from the polymeric field case. An electric box assembly including a plastic component box is disposed between the field case and a front section of the band saw. A crash guard is mounted adjacent to the field case and includes a sight guide along an edge thereof and a rear blade guard formed integrally therewith.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. patent application Ser. No.12/362,766 which claims the benefit of U.S. Provisional Application No.61/025,217, filed on Jan. 31, 2008.

FIELD

The present disclosure relates to various improvements to a portableband saw.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Many tradespersons, such as pipe fitters, steam fitters andelectricians, routinely cut metal workpieces such as pipes, tubes andconduit with portable hand-held power saws. In some applications, suchas when the end of a pipe or conduit is to be threaded, it is highlydesirable that the cut be perpendicular to the axis of the workpiece sothat the maximum axial deviation or runout of the cut is less than aboutone-thirty second of an inch. When this degree of accuracy is needed,the tradesperson was typically forced to employ a free-standing cutoffsaw or a portable hand-held band saw. Free-standing cutoff saws,however, are not typically practical due to issues with their cost andsize, as well as the free-standing (i.e., non-portable) nature of thesaw.

Although portable hand-held band saws provide the tradesperson with anefficient yet portable means for cutting work pieces, these tools can beimproved by improving their maintenance and damage prevention,increasing their functionality, reducing their weight and improving theaccuracy of a cut made by the band saw.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

A portable band saw includes a serviceable/replaceable bumper system forallowing the band saw to be easily repaired if damaged from beingdropped. The bumper system includes a rigid shroud removably mounted tothe band saw and an elastomeric bumper mounted to said rigid shroud.

An auxiliary handle is adjustably mounted to the band saw and isreleasable from its position if subjected to a large force so as toavoid damage to the handle and tool housing. The front section of theband saw includes at least one bore receiving a spring biased inserthaving at least one of a detent and a protrusion for engaging the otherof a detent and a protrusion on the handle. The spring biased insertallows the handle to disengage from the insert when subjected to a largeforce, such as by being dropped.

An adjustable guide shoe is provided that includes a toolless adjustmentmechanism to allow the position of the guide shoe to be easily adjusted.

The front and rear section of the band saw are disposed on oppositesides of a polymeric field case. Compression rods are used to isolatecompression forces from the polymeric field case.

An electric box assembly including a plastic component box is disposedbetween the field case and a front section of the band saw. The plasticcomponent box can house a control module and a light power supply. Oneor more routing cavities can extend from the component box and provide acovering for a wire of a wire harness connected to said control module.A light emitting diode can be mounted to a routing cavity of thecomponent box and can be aligned with the band saw blade to cast ashadow along the cut line.

A crash guard is mounted adjacent to the field case for protecting thefiled case from damage. The crash guard can include a sight guide alongan edge thereof and a rear blade guard formed integrally therewith forshielding the user from the return blade.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of a portable band saw according to theprinciples of the present disclosure;

FIG. 2 is an exploded perspective view of the portable band saw shown inFIG. 1;

FIG. 3 is a perspective view of the portable band saw shown in FIG. 1with the auxiliary handle shown in exploded view;

FIG. 4 is a perspective view of the portable band saw shown in FIG. 3illustrating the assembly of the auxiliary handle;

FIG. 5 is a perspective view of the portable band saw shown in FIG. 4with the auxiliary handle shown removed to illustrate the spring biasedinserts.

FIG. 6 is a perspective view of the auxiliary handle;

FIG. 7 is a side plan view of the portable band saw showing theauxiliary handle in a forward position;

FIG. 8 is a side plan view of the portable band saw showing theauxiliary handle in a upright position;

FIG. 9 is a side plan view of the portable band saw showing theauxiliary handle in an angled position;

FIG. 10 is a perspective view of the portable band saw shown in FIG. 1with the front and rear bumpers shown in exploded view;

FIG. 11 is an exploded perspective view of the front shroud and bumperassembly;

FIG. 12 is an exploded perspective view of the bumper assembly;

FIG. 13 is an exploded perspective view of the rear bumper assembly;

FIG. 14 is a perspective view of the portable band saw with the fieldcase removed to illustrate the compression rods and tension bolts of thepresent disclosure;

FIG. 15 is a partially exploded view of the portable band sawillustrating the electric box assembly of the present disclosure;

FIG. 16 is plan view of the wire harness according to the principles ofthe present disclosure;

FIG. 17 is a perspective view of the electric box assembly of thepresent disclosure;

FIG. 18 is an exploded perspective view of the electric box assembly ofthe present disclosure;

FIG. 19 is perspective view of a rear of the portable band saw accordingto the principles of the present disclosure;

FIG. 20 is a perspective view of the portable band saw shown in FIG. 1with the adjustable shoe shown in exploded view;

FIG. 21 is a perspective view of the shoe body;

FIG. 22 is partial cut away view illustrating the adjustable shoeaccording to the principles of the present disclosure;

FIG. 23 is a perspective view of the crash guard mounted to the fieldcase according to the principles of the present disclosure;

FIG. 24 is an exploded perspective view of the crash guard and fieldcase according to the principles of the present disclosure;

FIG. 25 is a rear perspective view of the crash guard mounted to thefield case and receiving the blade in a rear blade guard portionaccording to the principles of the present disclosure;

FIG. 26 is top view of the field case illustrating the sight guideaccording to the principles of the present disclosure;

FIG. 27 is a perspective view of a portable band saw illustrating thelight system according to the principles of the present disclosure;

FIG. 28 is perspective view of the light assembly according to theprinciples of the present disclosure; and

FIG. 29 is an exploded perspective view of the light assembly accordingto the principles of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.Although the following description is related generally to portable bandsaws, it will be understood that the systems and features of theportable band saw, as described and claimed herein, can be used with anyappropriate portable tool, such as an appropriate portable cuttingdevice, for example, a circular saw, reciprocating saw, etc. Therefore,it will be understood that the following discussions are not intended tolimit the scope of the appended claims.

With reference to FIG. 1, a portable band saw 10 is shown. The portableband saw 10 can be used to cut through various metal, metal alloy and/orpolymeric work-pieces. The portable band saw 10 can include a housing12, a power system 14, a saw blade system 16 and a lighting system 18.The housing 12 can enclose and/or support each of the power system 14,the saw blade system 16 and the lighting system 18. The power system 14can power the saw blade system 16, such that the saw blade system 16 cancut through the desired structure. The lighting system 18 can illuminatea work surface associated with the cutting operation of the saw bladesystem 16 to facilitate the operation of the portable band saw 10.

With reference to FIGS. 1 and 2, the housing 12 can include a first orfront section 20 and a second or rear section 22, which can be joinedtogether by a field case 21, one or more compression rods 24 and atleast one tension screw/bolt 26. As the front section 20 and the rearsection 22 of the housing 12 can be substantially similar to a housingassociated with a commercially available Heavy-Duty Deep Cut VariableSpeed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co.of Baltimore, Md., the front section 20 and the rear section 22 will notbe discussed in great detail herein. Briefly, however, the front section20 and rear section 22 can be composed of a metal or metal alloymaterial, and can comprise cast aluminum alloy or magnesium alloy, forexample. The front section 20 can include a first or auxiliary handle28, while the rear section 22 can include a second or trigger handle 30.Each of the front section 20 and the rear section 22 can include abumper system 32.

The auxiliary handle 28 can provide additional stability for the user ofthe portable band saw 10, and can be indexed at multiple angles toenable the user to select a comfortable position for the operation ofthe portable band saw 10, which can improve the ease of use of theportable band saw 10. The auxiliary handle 28 can be coupled to thefront section 20 of the housing 12 and can pivot or rotate relative tothe housing 12. With additional reference to FIGS. 3-6, the auxiliaryhandle 28 can include a knob 34 (FIGS. 3 and 4), a washer 36 (FIG. 4), afirst insert 38 (FIGS. 3 and 5), a second insert 40 (FIGS. 3 and 5), ahandle body 42 (FIGS. 3, 4 and 6) and a carriage bolt 44 (FIGS. 3 and4).

With reference to FIGS. 3 and 4, the knob 34 can comprise any suitablegraspable portion that can enable a user to easily rotate the knob 34 ina clockwise or counterclockwise direction while the user is holding thetrigger handle 30. The knob 34 can be rotated relative to the housing 12in a clockwise direction to secure the auxiliary handle 28 to thehousing 12, and can be rotated in a counterclockwise direction torelease the auxiliary handle 28 from the housing 12. In this regard, theknob 34 can include a bore 34 a. The bore 34 a can include threads,which can threadably engage mating threads 44 a on the carriage bolt 44.Thus, the rotation of the knob 34 relative to the housing 12 can movethe knob 34 along the threads 44 a of the carriage bolt 44 to eithertighten or lock the auxiliary handle 28 on the housing 12, or to releaseor loosen the auxiliary handle 28 relative to the housing 12, and thus,enable the auxiliary handle 28 to be pivoted or indexed relative to thehousing 12.

With reference to FIG. 4, the washer 36 can be positioned between theknob 34 and the first insert 38 to distribute the tightening orcompressive force from the knob 34 over a surface of the first insert38. With reference to FIGS. 3 and 5, the first insert 38 can be coupledto a first bore 46 formed in the housing 12, and the second insert 40can be coupled to a second bore 48 formed in the housing 12. It shouldbe noted that although the first bore 46 and second bore 48 areidentified as separate bores, the first bore 46 and second bore 48 couldcomprise a single bore formed through the housing 12. Typically, thefirst bore 46 can be formed opposite the second bore 48. The firstinsert 38 and second insert 40 can be coupled to the first bore 46 andsecond bore 48 through any suitable fastening technique, such as throughthe use of mechanical fasteners, a press-fit, a snap fit, welding andthe like. Alternatively, the inserts 38, 40 can be provided with flatsthat orient the inserts within the 46, 48 and springs 41 (FIG. 5) can bedisposed within the bores 46, 48 to bias the inserts toward the handle42. Generally, the first insert 38 and second insert 40 can be composedof a resilient material, which can comprise a metal, metal alloy,polymer or combinations thereof. For example, the first insert 38 andsecond insert 40 can be composed of a metal or metal alloy and a polymercan be overmolded onto the metal or metal alloy, if desired. The firstinsert 38 and second insert 40 can each include multiple detents 38 a,40 a, which can engage protrusions 42 a formed on the handle body 42(FIG. 3). The multiple detents 38 a, 40 a can enable the handle body 42to be pivoted or indexed and secured to the housing 12 in a variety ofpositions. The springs 41 allow the inserts 38, 40 to be retracted outof engagement with the protrusions 42 a of the handle body when thehandle 42 is subjected to a large force, such as by being dropped. Theability of the handle to move when subject to a large force, protectsthe handle 42 and housing from being damaged if dropped.

With reference to FIGS. 3 and 6, the handle body 42 can be generallyU-shaped, and can include the protrusions 42 a. The protrusions 42 a canbe formed on opposite annular projections 50. The protrusions 42 a canbe sized to engage the detents 38 a, 40 a to enable the handle body 42to be secured or coupled to the housing 12 in any desired position.Generally, with reference to FIGS. 7-9, the handle body 42 can be angledor indexed relative to the housing 12 in any position from about zerodegrees (FIG. 7) to about ninety degrees (FIG. 8). For example, as shownin FIG. 9, the handle body 42 can be coupled to the housing 12 at aboutforty-five degrees. With reference back to FIG. 6, the annularprojections 50 can include throughbores 52. The throughbores 52 canslideably engage the carriage bolt 44 to enable the handle body 42 torotate or pivot about the carriage bolt 44 when the knob 34 is rotatedaccordingly, as shown in FIGS. 3 and 4.

With reference to FIGS. 3 and 4, the carriage bolt 44 can include thethreads 44 a and a head 44 b. The threads 44 a can engage the bore 34 aof the knob 34 to enable the handle body 42 to be secured to or releasedfrom the housing 12. The head 44 b can be sized such that the head 44 bcan apply a compressive force against one of the annular projections 50of the handle body 42 when the auxiliary handle 28 is coupled to thehousing 12, as shown best in FIGS. 7-9.

With reference to FIG. 1, the trigger handle 30 can be coupled to therear portion 22 of the housing 12. As the trigger handle 30 can besubstantially similar to a trigger handle associated with thecommercially available Heavy-Duty Deep Cut Variable Speed Band Saw,model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore,Md., the trigger handle 30 will not be discussed in great detail herein.Briefly, however, the trigger handle 30 can enable the user to activateor deactivate the portable band saw 10, and can enable the user to guidethe portable band saw 10 over a work-piece.

The housing 12 can include the bumper system 32, as shown in FIG. 1. Thebumper system 32 can be coupled to the front section 20 and the rearsection 22. The bumper system 32 can protect the portable band saw 10from inadvertent falls from various heights. Further, the bumper system32 can be easily replaceable such that the user of the portable band saw10 can replace the bumper system 32 himself or herself at a job site,without requiring the user to take the portable band saw 10 to a servicestation. The bumper system 32 can generally be configured to absorb asignificant shock load, which can thereby prevent damage to the housing12. By preventing damage to the housing 12, the portable band saw 10 mayremain operable after a significant fall. With additional reference toFIG. 10, the bumper system 32 can include a front bumper 54 that can becoupled to the front section 20, and a rear bumper 56 that can becoupled to the rear section 22.

With reference to FIGS. 10-12, the front bumper 54 can include a shroud54 a and a bumper 54 b. The shroud 54 a can be shaped to conform to ashape of the front section 20, and can include a first or top surface60, a second or side surface 62 and one or more coupling features 64.The shroud 54 a can be a monolithic member, but could also comprise oneor more members to enable partial replacement of the front bumper 54, ifdesired. The shroud 54 a can be composed of any suitable high strengthmaterial, such as a metal, metal alloy or polymer, and for example,steel. The shroud 54 a can be coupled to the front section 20, via anysuitable mechanical fastening technique, such as through a snap-fit orthe use of mechanical fasteners, for example, rivets, bolts, screws,etc. Generally, as shown in FIG. 10, the top surface 60 can protect atop surface 20 a of the front section 20, while the side surface 62 canprotect an annular area 20 b below the top surface 20 a of the frontsection 20. The coupling features 64 can couple the top surface 60 ofthe shroud 54 a to the top surface 20 a of the front section 20, and cancouple the side surface 62 to the annular area 20 b. If mechanicalfasteners are employed to couple the shroud 54 a to the housing 12, thenthe coupling features 64 can comprise apertures, however, it will beunderstood that the coupling features 64 can comprise any desiredfeature to attach the shroud 54 a to the housing 12, such as matingprojections.

With continuing reference to FIGS. 10-12, the bumper 54 b can be shapedto conform to a shape of the side surface 62 of the shroud 54 a, and asbest shown in FIG. 12, can include an insert 66, a polymeric member 68and one or more coupling features 70. The bumper 54 b can be amonolithic member, but could also comprise one or more members to enablepartial replacement of the front bumper 54, if desired. The insert 66can be composed of any suitable high strength material, for example, ametal, metal alloy or polymer, such as steel. The insert 66 can providethe bumper 54 b with added rigidity. The insert 66 can be disposedadjacent to the side surface 62 of the shroud 54 a when the bumper 54 bis coupled to the shroud 54 a.

The polymeric member 68 can be coupled adjacent to a surface 66 a of theinsert 66. The polymeric member 68 can be coupled to the insert 66through any suitable technique, such as by overmolding the polymericmember 68 onto the insert 66, or by insert molding the insert 66 withinthe polymeric member 68. The polymeric member 68 can be composed of anysuitable shock absorbing material, for example, rubber. The couplingfeatures 70 can couple the bumper 54 b to the shroud 54 a. The bumper 54b can be coupled to the shroud 54 a, via any suitable mechanicalfastening technique, such as through a snap-fit or the use of mechanicalfasteners, for example, rivets, bolts, screws, etc. If mechanicalfasteners are employed to couple the bumper 54 b to the housing 12, thenthe coupling features 70 can comprise apertures that extend through boththe insert 66 and the polymeric member 68, however, it will beunderstood that the coupling features 70 can comprise any desiredfeature to attach the bumper 54 b to the housing 12, such as matingprojections.

With reference to FIG. 10, the rear bumper 56 can be coupled to the rearsection 22 of the housing 12. Generally, the rear bumper 56 can becoupled to a side 22 a of the rear section 22, to protect an annulararea surrounding a top surface 22 b of the rear section 22. The rearbumper 56 can be annular, however, the rear bumper 56 can be shaped asdesired to conform to the shape of the rear section 22. The rear bumper56 can be a monolithic member, but could also comprise one or moremembers to enable partial replacement of the rear bumper 56, if desired.With reference to FIG. 13, the rear bumper 56 can include an insert 72,a polymeric member 74 and one or more coupling features 76.

The insert 72 can be composed of any suitable high strength material,for example, a metal, metal alloy or polymer, such as steel. The insert72 can provide the rear bumper 56 with added rigidity. The insert 72 canbe disposed adjacent to the side 22 a of the rear section 22 when therear bumper 56 is coupled to the rear section 22.

The polymeric member 74 can be coupled adjacent to a surface 72 a of theinsert 72. The polymeric member 74 can be coupled to the insert 72through any suitable technique, such as by overmolding the polymericmember 74 onto the insert 72, or by insert molding the insert 72 withinthe polymeric member 74. The polymeric member 74 can be composed of anysuitable shock absorbing material, for example, rubber.

The coupling features 76 can couple the rear bumper 56 to the rearsection 22. The rear bumper 56 can be coupled to the rear section 22,via any suitable mechanical fastening technique, such as through asnap-fit or the use of mechanical fasteners, for example, rivets, bolts,screws, etc. If mechanical fasteners are employed to couple the rearbumper 56 to the housing 12, then the coupling features 76 can compriseapertures that extend through both the insert 72 and the polymericmember 74, however, it will be understood that the coupling features 76can comprise any desired feature to attach the rear bumper 56 to thehousing 12, such as mating projections.

With reference to FIG. 2, the field case 21 can be coupled between thefront section 20 and the rear section 22 of the housing 12. Generally,the field case 21 can be composed of a polymeric material, and can houseat least a portion of the power system 14. The field case 21 can includea first bore 21 a, a second bore 21 b and a third bore 21 c. The firstbore 21 a, the second bore 21 b and the third bore 21 c can extend atleast partially through the field case 21. For example, the first bore21 a and the second bore 21 b can be formed in the field case 21 suchthat a center area of the first bore 21 a and second bore 21 b can bedevoid of the field case 21 to enable a portion of the saw blade system16 to be coupled to the field case 21, via the compression rods 24, aswill be discussed. The first bore 21 a and the second bore 21 b can bedisposed at one side of the field case 21 and can be sized to receivethe compression rods 24. The third bore 21 c can pass through a side ofthe field case 21 opposite the first bore 21 a and second bore 21 b. Thethird bore 21 c can be sized to receive the tension screw/bolt 26.

With reference to FIGS. 2 and 14, the compression rods 24 can be coupledbetween the front section 20 and the rear section 22. A firstcompression rod 24 a can be received in the first bore 21 a, and asecond compression rod 24 b can be received in the second bore 21 b ofthe field case 21, as shown in FIG. 14. The front section 20 and therear section 22 can retain the compression rods 24 within the field case21. The compression rods 24 can receive a compression load C that can begenerally inherent in the portable band saw 10, and thus, thecompression rods 24 can relieve the field case 21 from the compressionload C, which can remove the compliant nature associated with the fieldcase 21 being composed of a polymeric material. The compression rods 24can also couple at least a portion of the saw blade system 16 to thefield case 21, as will be discussed herein.

With continued reference to FIGS. 2 and 14, the tension screw/bolt 26can be received through the third bore 21 c of the field case 21, andcan extend from the front section 20 to the rear section 22. The tensionscrew/bolt 26 can be threaded into a bore 80 defined in the rear section22, which can serve to retain the tension screw/bolt 26 within the bore21 c. The tension screw/bolt 26 can receive a tension or tensile load Tthat can be generally inherent in the portable band saw 10, and thus,the tension screw/bolt 26 can relieve the field case 21 from the tensileload T, which can remove the compliant nature associated with having thefield case 21 composed of a polymeric material.

With reference to FIG. 15, the power system 14 can be encased by thehousing 12. The power system 14 can drive the saw blade system 16 to cutthe work-piece. The power system 14 can include a trigger 100, a motor102 and a control system 104 via one or more wires 100 b (shown in FIG.16). As the trigger 100 and motor 102 can be substantially similar to atrigger and motor associated with a commercially available Heavy-DutyDeep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALTIndustrial Tool Co. of Baltimore, Md., the trigger 100 and motor 102will not be discussed in great detail herein. Briefly, however, thetrigger 100 can include an actuator 100 a that can be in communicationwith the control system 104. The actuator 100 a can protrude from thetrigger handle 30 to enable a user to activate or deactivate theportable band saw 10. Based on the input from the user, the actuator 100a can transmit a signal to the control system 104 to activate the motor102.

With reference to FIG. 15, the motor 102 can be a DC motor, such as abrushless DC motor. The motor 102 can be housed in the field case 21,and can be responsive to and in communication with the control system104. The motor 102 can also be coupled to the saw blade system 16, viaan output shaft, for example, to drive the saw blade system 16. As willbe discussed, based on the input received by the actuator 100 a, thecontrol system 104 can provide the motor 102 with an appropriate currentat an appropriate voltage phase angle to drive the saw blade system 16.

The control system 104 can be coupled to a first end 21 d of the fieldcase 21, adjacent to the motor 102. The control system 104 can beoperable to activate and deactivate the motor 102 based on the userinput received from the trigger 100. With reference to FIGS. 15-18, thecontrol system 104 can include a component box 106 (FIGS. 15, 17 and18), a controller 108 (FIG. 18), a lighting power supply 110 (FIG. 18)and a wiring harness 112 (FIGS. 16-18).

With reference to FIGS. 17 and 18, the component box 106 can be composedof a polymeric material, which can serve to electrically insulate theelectrical components within the component box 106 from the metallicportions of the housing 12, such as the front section 20 and the rearsection 22. The component box 106 can include apertures 114, a componentcavity 116, a first routing cavity 118, a second routing cavity 120, andcoupling members 122. The apertures 114 can receive mechanicalfasteners, such as screws, bolts, etc. to couple the component box 106to the field case 21. The component cavity 116 can be generallyrectangular, and can have a depth sized to receive and retain thecontroller 108 and the lighting power supply 110 within the componentbox 106, as shown in FIG. 17. The first routing cavity 118 and secondrouting cavity 120 can be sized to enable wires from the wiring harness112 to be routed away from the metallic portions of the housing 12. Thecoupling members 122 can retain the controller 108 and the lightingpower supply 110 within the component box 106. The coupling members 122can comprise flexible arms to enable the controller 108 and the lightingpower supply 110 to be inserted into the component box 106.

With reference to FIG. 18, the controller 108 can be in communicationwith and responsive to the trigger 100 and the motor 102 to enable theoperation of the portable band saw 10, as will be discussed. Thecontroller 108 can also be in communication with and responsive to thelighting system 18 to activate or deactivate the lighting system 18, aswill also be discussed herein. It should be understood that as usedherein, the term controller refers to an application specific integratedcircuit (ASIC), an electronic circuit, a processor (shared, dedicated,or group) and memory that execute one or more software or firmwareprograms, a combinational logic circuit, or other suitable componentsthat provide the described functionality. Further, as the controller 108can be substantially similar to a controller associated with acommercially available Heavy-Duty Deep Cut Variable Speed Band Saw,model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore,Md., the controller 108 will not be discussed in great detail herein.Briefly, however, the controller 108 can provide a selected current at aselected voltage phase angle to the motor 102 from a field power source(not shown) based on the signal received from the actuator 100 a. Thecontroller 108 can also provide current to the lighting system 18 fromthe lighting power supply 110 based on a signal received from thelighting system 18, as will be discussed.

With reference to FIG. 18, the lighting power supply 110 can compriseany suitable power source capable of providing current to the lightingsystem 18, such as a battery, capacitor, etc. The lighting power supply110 can include members 110 a to couple the wiring harness 112 to thecomponent box 106. The wiring harness 112 can include apertures formedin a projection 112 a that can receive the members 110 a to couple thewiring harness 112 to the component box 106. Generally, the wiringharness 112 can be press-fit onto the members 110 a.

With reference to FIG. 16, the wiring harness 112 can include one ormore controller connections 124, a lighting connection 126, a lightingpower supply connection 128 and a feedback coil 130. The controllerconnections 124, the lighting connection 126, the lighting power supplyconnection 128 and the feedback coil 130 can be overmolded with apolymeric material to form the wiring harness 112. As the controllerconnections 124, the lighting connection 126 and the lighting powersupply connection 128 can be similar to the connections employed withthe commercially available Heavy-Duty Deep Cut Variable Speed Band Saw,model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore,Md., the controller connections 124, the lighting connection 126 and thelighting power supply connection 128 will not be discussed in greatdetail herein. The feedback coil 130 can be disposed within a center 132of the overmolded wiring harness 112, which can be adjacent to the motor102 when the component box 106 is coupled to the field case 21. Thefeedback coil 130 can sense the magnetic field generated by the motor102, and can communicate this information to the controller 108 via anappropriate one of the controller connections 124. Based on the signalfrom the feedback coil 130, the controller 108 can increase or decreasethe speed of the motor 102. By incorporating the feedback coil 130within the center 132 of the overmolded wiring harness 112, the feedbackcoil 130 can remain in the same position during the use of the portableband saw 10, which can improve the accuracy of the signal received fromthe feedback coil 130.

With reference to FIG. 19, the saw blade system 16 can be driven by themotor 102 of the power system 14. The saw blade system 16 can include ablade 200, one or more pulleys 202, a shoe 204, a crash plate system 206and a sight guide 208. The blade 200 can comprise a conventional bandsaw blade, such as a Bi-Metal Portable Band Saw Blade, model DW3891,commercially available from DeWALT Industrial Tool Co. of Baltimore, Md.The pulleys 202 can be substantially similar to pulleys associated withthe commercially available Heavy-Duty Deep Cut Variable Speed Band Saw,model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore,Md., and thus, the pulleys 202 will not be discussed in great detailherein. Briefly, however, one of the pulleys 202 can be coupled to themotor 102 to drive the blade 200 around the housing 12.

With reference to FIGS. 20-22, the shoe 204 can be positioned adjacentto the work-piece to support the work-piece during the operation of theportable band saw 10. The shoe 204 can be configured to enable the userof the portable band saw 10 to adjust a position of the shoe 204relative to the work-piece without requiring tools. The shoe 204 caninclude a shoe body 210, a block 212, a stud 214 and a lever 216.

With reference to FIGS. 20 and 21, the shoe body 210 can define a firstend 218, a second end 220, a first or front side 222 and a second orrear side 224. The first end 218 can include one or more apertures 226and a blade passage 228. The apertures 226 can be sized to receive oneor more mechanical fasteners 226 a, such as screws, bolts, etc., tocouple the shoe body 210 to the block 212. The blade passage 228 canenable the blade 200 to pass through the shoe body 210. The second end220 of the shoe body 210 can be positioned adjacent to the work-piecewhen the shoe 204 is coupled to the housing 12. The front side 222 canface the front section 20 when the shoe 204 is coupled to the rearsection 22. The rear side 224 can be opposite the front side 222, andthus, can be adjacent to the rear section 22 when the shoe 204 iscoupled to the rear section 22. The rear side 224 can also include a lip224 a (FIG. 21). The lip 224 a can cooperate with the block 212 tocouple or clamp the shoe body 210 to the rear section 22 of the housing12.

The block 212 can be coupled to the shoe body 210 via the mechanicalfasteners 226 a. The block 212 can include a projection 230, a clampingsurface 232 and mating features 234. With reference to FIG. 22, theprojection 230 can be generally elliptical, and can be sized to slidewithin a slot 236 formed in the rear section 22 of the housing 12. Aswill be discussed, the block 212 can cooperate with the slot 236 toenable the shoe body 210 to be positioned and secured in any desiredposition along a length of the slot 236. The slot 236 can comprise aT-slot to enable only the projection 230 of the block 212 to be receivedin and slide within the slot 236. As shown in FIG. 20, the projection230 can define apertures 230 a for receipt of the mechanical fasteners226 a to couple the block 212 to the shoe body 210, and thus, theapertures 230 a can be threaded, if necessary, to mate with themechanical fasteners 226 a.

With reference to FIGS. 20 and 22, the clamping surface 232 cancooperate with the lip 224 a to couple or clamp the shoe 204 to the rearsection 22 of the housing 12. In this regard, the rear section 22 of thehousing 12 can include a rail 238 adjacent to the slot 236 (FIG. 22).When the projection 230 is positioned within the slot 236, the lip 224 acan abut against a first side of the rail 238 and the clamping surface232 can abut against a second side of the rail 238 to clamp the shoe 204to the housing 12. With reference to FIG. 21, the clamping surface 232can include a taper 232 a. The taper 232 a can enable the block 212 tobe forced tightly against the rail 238 to firmly clamp the shoe body 210to the housing 12.

With reference to FIGS. 20-22, the mating features 234 can be defined ona surface opposite the clamping surface 232. The mating features 234 caninclude any feature capable of engaging the stud 214 in a variety ofpositions, such as ridges, angled projections, detents, etc. The matingfeatures 234 can engage the stud 214 such that a force applied to thestud 214, via the lever 216, can be applied to the block 212 to clampthe shoe 204 to the housing 12. Thus, the mating features 234 cancooperate with the stud 214 to lock or secure the shoe 204 in a desiredvertical position relative to the housing 12.

With reference to FIGS. 20 and 22, the stud 214 can include a first end240 and a second end 242. The first end 240 of the stud 214 can includeat least one mating feature 240 a. The mating feature 240 a can beconfigured to engage the mating features 234 on the block 212 totransmit a torque from the lever 216 to the block 212 to clamp the shoe204 to the housing 12. For example, if the mating features 234 of theblock 212 comprise angled projections, then the mating feature 240 a ofthe stud 214 can comprise a valley. The second end 242 of the stud 214can be configured to couple the lever 216 to the stud 214, and thus, thesecond end 242 can define a bore that can be threaded, keyed, notched,etc. to couple the lever 216 to the stud 214.

With reference to FIGS. 20 and 22, the lever 216 can include a first end216 a that can couple the lever 216 to the stud 214, and a second end216 b that can receive an input from the user of the portable band saw10. The first end 216 a can be configured to mate within the bore 242 aof the second end 242 of the stud 214, and thus, the first end 216 a canbe threaded, keyed, notched, etc. to fixedly couple the lever 216 to thestud 214. In addition, it should be understood that although the stud214 and lever 216 are described herein as being discrete elements, thestud 214 and lever 216 could also be integrally formed. The second end216 b of the lever 216 can be sized such that the user can easily graspthe lever 216 to rotate the lever 216 clockwise or counterclockwiserelative to the housing 12. In this regard, the lever 216 can be rotatedclockwise to apply the torque to the block 212, via the stud 214, toclamp the shoe 204 in a desired position relative to the housing 12. Thelever 216 can be rotated counterclockwise to release the torque from theblock 212, by disengaging the mating features 234 of the block 212 fromthe mating feature 240 a of the stud 214, to enable the projection 230of the block 212 to be slid into a desired position within the slot 236.Thus, the lever 216 can enable tool-less adjustment of the shoe 204relative to the housing 12, which can enable quick adjustments of theshoe 204 on a job site.

With reference to FIGS. 19 and 23-25, the saw blade system 16 can alsoinclude the crash plate system 206. The crash plate system 206 canprotect a bottom 250 of the field case 21 from damage that may be causedby the portable band saw 10 contacting the work-piece after the cuttingoperation due to the inherent follow through motion of the portable bandsaw 10. The crash plate system 206 can include a crash plate 252 and ablade guard 254. The crash plate 252 and blade guard 254 can be discretemembers, or can be integrally formed into a monolithic member. The crashplate 252 and blade guard 254 can be composed of any suitable highstrength material, such as a metal, metal alloy or resilient polymer.The crash plate 252 can protect the field case 21 from damage, while theblade guard 254 can protect the user from a rear section 200 a of theblade 200 (FIG. 25).

The crash plate 252 can be configured to mate with the bottom 250 of thefield case 21, and for example, can be generally concave in shape. Asshown in FIG. 24, the crash plate 252 can also be sized to fit in thevoid defined between the first bore 21 a and second bore 21 b of thefield case 21, so that the compression rods 24 a, 24 b can be used tocouple the crash plate 252 to the field case 21. It will be understoodthat any suitable technique could be used to couple the crash plate 252to the field case 21, such as welding, adhesives, mechanical fasteners,etc. The crash plate 252 can include a top surface 256, a rear surface258, a first side 260, a second side 262 and throughbores 264.

With reference to FIGS. 23 and 24, the top surface 256 can be positionedadjacent to the field case 21, and can be generally smooth to mate witha generally smooth exterior of the field case 21. The rear surface 258can be opposite the top surface 256, and can include one or more crushribs 258 a. The crush ribs 258 a can absorb and distribute forcesincurred when the portable band saw 10 inadvertently contacts thework-piece. The first side 260 can be coupled to the sight guide 208,and the second side 262 can be coupled to the blade guard 254. Thethroughbores 264 can be sized to slideably receive the compression rods24 therethrough to couple the crash plate 252 to the field case 21 (FIG.23).

With reference to FIGS. 19 and 23-25, the blade guard 254 can be coupledto or formed on the second side 262 of the crash plate 252. Asdiscussed, the blade guard 254 can protect or guard the user from therear portion 200 a of the blade 200 (FIG. 25), and can also shield theblade 200 from debris or objects adjacent to the work-piece. The bladeguard 254 can define a passage 254 a. The passage 254 a can be sized toenable the blade 200 to pass therethrough, and can generally have adepth configured such that a majority of the blade 200 is disposedwithin the passage 254 a.

With reference to FIGS. 24 and 26, the sight guide 208 can be coupled tothe first side 260 of the crash plate 252 (FIG. 24). In this regard, thesight guide 208 can be coupled to the first side 260 such that the sightguide 208 can extend substantially an entire length of the first side260 of the crash plate 252. The sight guide 208 can be comprised of anysuitable material, such as a metal, metal alloy or polymer, that can becoated with a color, which contrasts with the field case 21, such asred, to enable the user to easily view the sight guide 208. The sightguide 208 can be coupled to the crash plate 252 via any suitabletechnique, such as molding, adhesives, mechanical fasteners, etc. Forexample, the sight guide 208 can comprise a polymeric material that canbe adhesively coupled to the crash plate 252, or the sight guide 208 cancomprise a polymeric coating, such as paint, that can be applied to thefirst side 260 of the crash plate 252. The sight guide 208 can assistthe user in predicting the cutting plane of the blade 200, withoutreducing or altering the blade 200. In use, the user can align the sightguide 208 with a line or scribe on the work-piece and maintain thisalignment throughout the cutting operation, which can assist the user inproducing accurate cuts.

With reference to FIGS. 27-29, the lighting system 18 can illuminate thework-piece, generally in an area adjacent to and encompassing thedesired cutting area or cutting path through the work-piece. Thelighting system 18 can be housed within the component box 106 of thecontrol system 104 on the front section 20 of the housing 12. Thelighting system 18 can include a light source 300 (FIG. 29), a printedcircuit board (PCB) 302 (FIG. 29), a baffle 304 (FIGS. 28 and 29), ahousing 306 (FIGS. 28 and 29) and a switch 308 (FIG. 27).

With reference to FIGS. 27 and 29, the light source 300 can comprise anysuitable light emitting device, such a light emitting diode (LED),organic light emitting diode (OLED), etc. If a LED is employed as thelight source 300, the LED can comprise a one-half watt LED. The lightsource 300 can emit light rays R onto the work-piece to aid the user inthe cutting operation. The light source 300 can be coupled to the PCB302.

With reference to FIG. 29, the PCB 302 can be in communication with andresponsive to the controller 104, via a connector 302 a, to receivepower or current from the lighting power supply 110. The PCB 302 caninclude suitable circuitry to power the light source 300 with the powerreceived from the lighting power supply 110. Upon receipt of the currentfrom the controller 104, the PCB 302 can activate the light source 300to illuminate the work-piece.

With reference to FIGS. 28 and 29, the baffle 304 can be positioned overthe light source 300 and the PCB 302. The baffle 304 can be generallyannular, and can be sized to surround the light source 300 and the PCB302 such that the PCB 302 is hidden from the view of the user. Thebaffle 304 can be composed of any suitable heat resistant material, suchas a metal, metal alloy or polymer. The baffle 304 can include a bore304 a, a shade 304 b and keys 304 c. The bore 304 a can be sized toenable the light source 300 and the PCB 302 to be retained within thebaffle 304. The shade 304 b can be generally V-shaped, and can cover atleast a portion of the light source 300. The shade 304 b can prevent thelight rays from the light source 300 from shining in the user's eyes.The keys 304 c can ensure that the baffle 304 is properly insertedwithin the housing 306, and that the baffle 304 does not rotate relativeto the housing 306.

The housing 306 can couple the lighting system 18 to the component box106. The housing 306 can be composed of any suitable material, such as ametal, metal alloy or polymer, and can generally comprise a translucentpolymer. The housing 306 can include a bore 306 a and at least onecoupling feature 306 b. The bore 306 a can be configured to receive thebaffle 304, and can include mating keys 312. The mating keys 312 canengage the keys 304 c of the baffle 304, which can ensure that thebaffle 304 is properly orientated and remains properly orientated withinthe housing 306. The coupling feature 306 b can couple the housing 306to the component box 106. For example, the coupling feature 306 b cancomprise a bore for receipt of a mechanical fastener, such as a screw,bolt, etc. to couple the housing 306 to the component box 106, as shownin FIG. 15.

With reference to FIGS. 15 and 27, the switch 308 can also be coupled tothe component box 106, and can be in communication with the controller108. The switch 308 can be coupled to the component box 106 such thatthe switch 308 can be easily manipulated by the user. In this regard,the switch 308 can enable the user to activate or deactivate the lightsource 300. Thus, based on the user input received, the switch 308 cantransmit a signal to the controller 108, which can then transmit orcease transmitting power to the PCB 302, effectively activating ordeactivating the light source 300.

In order to assemble the lighting system 18, the light source 300 can becoupled to the PCB 302, and that assembly can be inserted into thebaffle 304. Then, the baffle 304 can be inserted into the housing 306,which can then be coupled to the component box 106. The user can thenmanipulate the switch 308 to activate or deactivate the light source300. Thus, the lighting system 18 can be easily assembled and coupled tothe portable band saw 10 to enable a user to selectively illuminate thework-piece, while not projecting light rays into the user's eyes.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the invention. Individual elements or features ofa particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the invention, and all such modificationsare intended to be included within the scope of the invention.

What is claimed is:
 1. A portable band saw, comprising: a housingincluding a front section and a rear section; a blade extending betweensaid front section and said rear section; and a shoe body adjustablyattached to said housing and including a blade passage for receivingsaid blade therein, said shoe body being secured to said housing by atoolless adjustment mechanism that adjustably engages a toothed block onsaid shoe body.
 2. The portable band saw according to claim 1, whereinsaid toolless adjustment mechanism includes a lever engaging a threadedstud that adjustable engages said toothed block.
 3. The portable bandsaw according to claim 1, wherein said toothed block is slidablydisposed in a slot in said housing.